Eaton Cutler-Hammer ELC Series Installation guide

Eaton Logic Controller
Basic Training (1 Hour)
January 2006
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 1

Preface
Information in this manual is subject to change without notice and does not
represent a commitment on the part of Eaton Electrical Inc. Permission is granted
to duplicate this material without modification only for your use or the internal use
of other members of your company or your agents to assist you in the use and
servicing of products purchased from Eaton Electrical. No permission is granted
to modify this material or include this material in a compilation.
Intro:
Preface
Support
Services
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Software
Overview
Hardware
Overview
Basics:
Exercises:
Go Chart
Support
Services
Preface
RESTRICTED RIGHTS LEGEND
Use, duplication, or disclosure by the Government is subject to restrictions set
forth in paragraph (b)(3)(B) of the Rights in Technical Data and Computer
Software clause of DAR 7-104.9(a). Contractor/Manufacturer is Eaton
Corporation, Operator Interface Business, 811 Green Crest Drive, Westerville,
OH 43081.
TRADEMARKS
PanelMate, Cutler-Hammer, Eaton and ePro Canvas are either federally
registered trademarks or trademarks of Eaton Corporation.
Commercial brand names (trademarks) of products of manufacturers or
developers, other than Eaton Corporation or its affiliates, that appear in this
manual may be registered or unregistered trademarks of those respective
manufacturers or developers, which have expressed neither approval nor
disapproval of Cutler-Hammer®products and services.
©2005 Eaton Electrical Inc. All rights reserved.
Printed in the United States of America.
P/N MN05003001E
Navigation in This Document
The cells to the left of the content on the even pages in this document are meant
to show your progress through the training. The chapter which you are currently
viewing is highlighted. For instance, on this page, the cells titled “Preface” and
“Support Services” are highlighted to show what you are viewing on this page
and the opposing page (in book format).
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 2

Support Services
The goal of Eaton is to ensure your greatest possible satisfaction with the operation of our products. We
are dedicated to providing fast, friendly and accurate assistance. That is why we offer you so many ways
to get the support you need. Whether it's by phone, fax or e-mail, you can access Eaton’s support
information 24 hours a day, seven days a week. Our wide range of services is listed below.
You should contact your local distributor for product pricing, availability, ordering, expediting and repairs.
Website
Use the Eaton Electrical website to find product information. You can also find information on local
distributors or Eaton’s Cutler-Hammer sales offices.
Website Address www.eatonelectrical.com
e-COM Support Center
Call the e-COM Support Center if you need assistance with placing an order, stock availability or proof of
shipment, expediting an existing order, emergency shipments, product price information, returns other
than warranty returns, and information on local distributors or sales offices.
e-COM Support Center Voice: 800-356-1243 (8a.m.–6p.m. EST)
FAX: [phone]
After-Hours Emergency: 800-543-7038
(6p.m.–8a.m. EST)
e-TRC Technical Resource Center
If you are in the US or Canada, and have OI/PLC/IPC questions, you can take advantage of our toll-free
line for technical assistance with hardware and software product selection, system design and
installation, and system debugging and diagnostics. Technical support engineers are available for calls
during regular business hours.
e-TRC
Technical Resource Center
(support for OI, PLC and IPC)
Voice:
•800-809-2772, selection 5 (8a.m.–5p.m. EST)
•414-449-7100, selection 5 (8a.m.–5p.m. EST)
FAX: [phone]
e-mail: [email protected]
After-Hours Emergency (Plant Down Only):
•800-809-2772, selection 5 (5p.m.–8a.m. EST)
•414-449-7100, selection 5 (5p.m.–8a.m. EST)
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 3

Go Chart
This document will take you through the following steps to learn the
basics of the ELC:
Intro:
Preface
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Software
Overview
Hardware
Overview
Basics:
Exercises:
Support
Services
Go Chart
Exercise 1: Basic
Project Programming
Exercise 2: Basic
Logic Instructions
Exercise 3: Timer &
Math Instructions
Exercises
Basics
Software Overview
Hardware Overview
Connecting to the ELC
Go Chart
Hardware
Overview
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 4

Hardware Overview
NOTE:
The following items are typical and may vary depending on
the model number of your ELC processor.
Item Description
1 Status Indicators:
•Power
•Error
•Run
•Batt. Low (units with Clk/Calendar)
2 Run/Stop switch
3 (2) Digital 7-segment displays (on select models)
4 Digital I/O terminals
5 Din rail clip
6 Analog I/O terminals
7 I/O point indicators
8 COM 1 (RS-232) (Rx) indicator
9 COM 2 (RS-485) (Tx) indicator
10 COM 1 (RS-232) programming port
11 EATON nameplate
12 Extension port
13 Receptacle for expansion unit
14 DIN rail slot (35mm)
15 Expansion unit clip
16 COM 2 (RS-485) communication port
17 DC power input
18 RS-485 cable (included accessory)
19 Power input cable (included accessory)
20 Battery cover
21 Battery socket connection
22 Battery mount
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 5

Hardware Overview
Model Number Explanation
Intro:
Preface
Use the following chart and tables to choose or identify your ELC components:
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Software
Overview
Hardware
Overview
Basics:
Exercises:
Support
Services
Go Chart
Processors
Description Inputs Outputs Catalog Listing
Processor/no Clk AC DC ALG RY TRN ALG
14 I/O PB Series 8 6 ELC-PB14NNDR
14 I/O PB Series 8 6 ELC-PB14NNDT
Processor With Clock
12 I/O PC Series 8 4 ELC-PC12NNAR
12 I/O PC Series 8 4 ELC-PC12NNDR
12 I/O PC Series 8 4 ELC-PC12NNDT
10 I/O PA Series 4 2 2 2 ELC-PA10AADR
10 I/O PA Series 4 2 2 2 ELC-PA10AADT
Hardware
Overview
Digital Expansion Modules
Description Inputs Outputs Catalog Listing
AC DC RY TRN
8 I/O Expansion 8 ELC-EX08NNAN
8 I/O Expansion 8 ELC-EX08NNDN
8 I/O Expansion 8 ELC-EX08NNNR
8 I/O Expansion 8 ELC-EX08NNNT
8 I/O Expansion 4 4 ELC-EX08NNDR
8 I/O Expansion 4 4 ELC-EX08NNDT
16 I/O Expansion 8 8 ELC-EX16NNDR
16 I/O Expansion 8 8 ELC-EX16NNDT
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Analog Expansion Modules
Description Inputs Outputs Catalog Listing
Analog In Analog Analog
4 I/O Analog In 4 ELC-AN04ANNN
Analog Out
2 I/O Analog Out 2 ELC-AN02NANN
4 I/O Analog Out 4 ELC-AN04NANN
Analog Combination
6 I/O Analog In/Out 4 2 ELC-AN06AANN
Temperature
4 I/O Thermocouple 4 ELC-TC04ANNN
4 I/O Platinum 4 ELC-PT04ANNN
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 7

Software Overview
PC Requirements
Intro:
Preface Component Requirement
Operating System Windows 95/98/2000/NT/ME/XP
CPU Pentium 90 and above
Memory 16MB and above (32MB and above is recommended)
Hard Disk Capacity: 50MB and above
CD-ROM (for installing ELCSoft)
Monitor Resolution Minimum: 640×480, 16 colors and above
Recommended: 800×600
Mouse Serial or Windows compatible mouse
Printer Printer with Windows driver
Comm Port (1) RS-232, labelled COM1 - COM8
Compatible Products All Eaton ELC series
Support
Services
Go Chart
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Hardware
Overview
Software
Overview
Basics:
Exercises:
Installing the software
Insert the provided CD-ROM into the proper drive on your PC. The install program
should automatically run.
Software
Overview
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 8

Software Overview
Software Features:
To open the software, select:
START>ALL PROGRAMS>ELCSOFT
The following menus will be described here as a quick primer on just a few of the ELCSoft
program features. Some of these features may be limited based on which ELC processor
you are using.
File
Options
Help
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 9

Software Overview
File Menu
Intro:
Preface
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Hardware
Overview
Software
Overview
Basics:
Exercises:
Support
Services
Go Chart
NEW: Opens the window to the right. Allows
you to give the new program a name (Program
Title); choose what ELC Type you will be
programming (you’ll know this type as part of the
ELC part number); and create a File Name that
the new project will be saved under.
OPEN: Opens a window to browse to an
already saved ELC project.
*SAVE: Saves an already open file to its
current filename.
Software
Overview *SAVE AS: Saves an open project file as a
name different than the one that is currently
saved under.
*CLOSE PROJECT: Closes the currently
open project and leaves the software open.
*PRINT: Opens the window to the
right. Allows you to specify what you’d
like to print and gives the option to
preview the printed result.
PRINTER SETUP: Opens a
standard printer setup window.
EXIT: Closes the ELCSoft software.
BELOW EXIT: Shortcuts to recently
used projects will appear in rows below
the Exit choice.
* Available only when a project is open.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 10

Software Overview
Options Menu
COMMUNICATION SETTING: Opens the window to the
right. Allows you to choose the COM Port, Baud Rate and
Station Address for communications to the ELC, along with
Retries and Retry Delay settings.
*CHANGE ELC TYPE: Opens the ELC Type Setting dialog
shown on page 10. Allows you to set the type of ELC on which
the currently open project will be used.
AUTOSAVE SETUP: Opens a window that allows you to
set software auto save features to occur either at the beginning
of a compile function or at a specific interval (minimum is 5
minutes). NOTE: By default, the Auto Save box is unchecked.
FONT SETTING AND COMMENT FORMAT: Opens a
window to configure colors and fonts used in the program.
*SET ELC DATE AND TIME: If an ELC is
connected, this opens the window to the right,
which lets you synchronize the clock in the
ELC.
PROMPT TO EDIT DEVICE
COMMENT: When this option is checked,
the software will automatically pop up a window
that has a field for entering a device comment
immediately after you enter an address by
direct typing command in a programming
window.
* Available only when a project is open.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 11

Software Overview
Help Menu
Intro:
Preface
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Hardware
Overview
Connecting to
the ELC
Software
Overview
Basics:
Exercises:
Support
Services
Go Chart
ABOUT ELCSOFT: Click here to view the version number of your ELCSoft software.
INTELLIGENT FUNCTION UTILITY: A submenu is available from this menu
choice that assists in the setup of advanced ELC functionality.
ELC INSTRUCTION & SPECIAL REGISTERS REFERENCE: Opens a help
file devoted that lists and defines all basic and advanced instructions and special function
registers (D) and words (M).
ELCSOFT USER MANUAL: Opens the ELCSoft User Manual.
Other helpful menu commands:
VIEW>WORKSPACE: Opens a treeview representation of the currently open
project to the left of the main programming window.
Connecting
to the ELC
Software
Overview SOME COMMANDS TO BE AWARE OF WHICH NEED LITTLE OR NO
EXPLANATION:
•VIEW MENU
oInstruction List
oLadder Diagram
oSFC Diagram (Sequence Function Chart [similar to flow chart])
oEdit Device Comments
oList of Used Devices
oCross Reference List
oShow Comments
oSymbol Table
•SEARCH MENU
oGo To
oSearch/Replace
oGo To Start
oGo To End
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 12

Connecting to the ELC
To connect to a new ELC:
•Open ELCSoft
•Use the ELC programming cable (part number ELC-CBPCELC3) to connect a serial port on
your PC to the port on the front of the ELC processor.
•Choose OPTIONS>COMMUNICATION SETTING, and choose the port to which the
programming cable is connected in the window. (NOTE: The Technical Support and Services team
has had success using various USB to serial converters to communicate to the ELC product line as well.)
•Set Station Address to 1.
•Select Communication>ELC Information.
oThe software will attempt to communicate to
the ELC.
•A window similar to the one shown here should
appear relatively quickly.
oIf this window does not appear, check the
cable connection and be sure that you have
the correct COM port and address chosen
under the Options menu. The software
should auto-detect the correct electrical
settings for ELC communications.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 13

Connecting to the ELC
The Communication menu will be described here because many of the
functions selectable in this menu are only available while connected to the
ELC.
Intro:
Preface Communication Menu
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Software
Overview
Hardware
Overview
Connecting to
the ELC
Basics:
Exercises:
Support
Services
Go Chart
TRANSFER SETUP: Opens the window to
the right. Used not only to send the currently
open project (or a portion of that project) to an
ELC or a handheld programmer; but also to
upload a project from an ELC that is connected
to the PC.
VERIFY WITH ELC: Verifies that the
currently open project is the same as the one
stored in an ELC that is connected to the PC.
PASSWORD SETTING: Used to set the
password in the ELC. The password is required for any communication to the ELC.
Once a password is set, the only way to gain access to the ELC memory is to have that
password. If you do not have the correct password, you can clear the memory in the
ELC to gain access. If you are working with a PB model ELC and have forgotten the
password, enter four spaces when requested for the password and a window will appear
to confirm that you want to delete the entire ELC program. If you are working with a PC,
PA or PH, remove the battery for 10 minutes or click COMMUNICATION>FORMAT ELC
MEMORY to delete the entire ELC program. Once the program is deleted, you will have
access to the ELC memory.
Connecting
to the ELC
RUN &STOP: Change the run state of the ELC. Note that the current state of the
ELC may be changed by the software no matter how the switch on the front of the
processor is set.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 14

Connecting to the ELC
LADDER START MONITORING: While connected to an ELC, this starts monitoring the current state of
the referenced bits in the ladder logic that is open in the software. This means that if the project in the ELC does
not match the project currently open in the ELCSoft, it may seem that the software is not working properly. The
best practice would be to use the VERIFY WITH ELC function first, then LADDER START MONITORING.
SFC START MONITORING: While connected to an ELC, this starts
monitoring the current state of the referenced programs in the Sequential
Function Chart. This is an advanced function that will be covered in future
training materials.
DEVICES BATCH MONITORING: Opens a window that allows you to
monitor a group of selected references in “spreadsheet” format.
*SET DEVICE ON/OFF: Opens the window to the right. Allows you to
set the state of any bit reference.
*ENTER VALUE: Opens the window to the
right. Allows value to be entered in a non-
binary reference.
EDIT REGISTER MEMORY: Allows you
to change the value of T, C, and D registers in
table view format and send the values to the
ELC.
EDIT BIT MEMORY: Allows you to
change the state of bits in table view format
and send the values to the ELC.
FORMAT ELC MEMORY: Gives options
for clearing program memory or formatting
ELC memory. Formatting ELC memory sets
the processor back to factory defaults.
EDIT FILE REGISTER MEMORY:
Allows you to change the value of file registers in table view format and send the values to the ELC.
SEND CHANGES: After making changes to an ELC project, you can send the changes to the ELC without
putting the processor into stop mode.
BAUD RATE AUTO-DETECT: Performs a check with the ELC that is connected to the selected port on the
PC and pops up a window that gives details about the ELC model the baud rate, data bits, stop bits and parity of
the communications that the ELCSoft package uses to communicate to the ELC processor, and the COM port
from which the PC is communicating to the processor.
ELC INFORMATION: This calls up the window that you should have seen earlier when you verified
communications between the PC and the ELC.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 15

Exercise 1: Ladder Logic Programming
In order to teach the basics of programming with ELCSoft,
we will practice with basic ladder functions.
Intro:
Preface Getting Started
•Choose FILE>NEW and give your new project a Program Title. Choose the Type of
ELC Processor you’ll use and create a File Name under which the project will be
saved.
TIP: If you select VIEW>WORKSPACE once you have created the new file, an
overview of the project in treeview format will appear on the left of the page. This
is a great help in understanding the “big picture” as you program.
TIP: All Exercises in this Basic Training will take place in Ladder Diagram Mode. Any
screenshots you see will have that window maximized.
Support
Services
Exercise 2: Logic
Instructions
Connecting to
the ELC
Software
Overview
Hardware
Overview
Exercise 1:
Ladder Logic
Basics:
Exercises:
Go Chart
Exercise 1:
Ladder Logic
•There are multiple ways to add objects to the ladder diagram. You can click on the
desired object in the Ladder Diagram Toolbar (see below); use the function key
associated with the desired object; or start entering the instruction code on your
keyboard when the Ladder Diagram Mode window is selected. To see a list of those
instruction codes, select HELP>ELC INSTRUCTION AND SPECIAL REGISTERS
REFERENCE.
Ladder Diagram Toolbar
Input Instruction Popup Window
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Exercise 1: Ladder Logic Programming
The finished result of this exercise will be this ladder running in the ELC:
•Click the icon that represents a normally
open contact in the Ladder Diagram
Toolbar (far left). The window to the
right will appear with the type of contact
you selected at the top.
•Select “M” from the Device Name pull
down list. Note that the description of
this type of reference changes to
“Internal Relay.”
•Leave the second window set for 0 and
click “OK”. A N.O. contact with the
reference “M0” will appear in the
window.
•Create a normally closed contact that
references “M1” in the next available
“cell”.
•While the next cell is highlighted, press the F7 key on your keyboard. The device input window will appear
with “Output coil” as the type of contact. Make this object reference “Y0”. Y0 is the first digital output on the
processor.
•With the first cell of line 2 highlighted, type LD Y0 on your keyboard. Case is not sensitive. The Input
instruction window will appear. “LD” is the command code for a normally open contact. (To see a list of those
codes, select HELP>ELC INSTRUCTION AND SPECIAL REGISTERS REFERENCE.) “Y0” is the bit that
we want to reference. Either click “OK” on that window or just press the enter key. The window will close and
the contact will appear in the cell that was highlighted.
•When drawing vertical lines to connect rungs, the line draws from the lower left corner of the selected cell
down to the rung below, so you will need to highlight the cell with the normally closed contact that references
M1 and then either press F9 on your keyboard or click the vertical line tool on the toolbar.
•Highlight the first cell in the third line of the diagram and type the word end and press enter. Choose
COMPILER>LADDER => INSTRUCTION to compile the project. This will complete your first simple latching
circuit program.
•To download the program to the ELC, choose COMMUNICATION>TRANSFER SETUP. Be sure that the
Selected Operation is “Write to ELC” and that Whole Range is selected in the range setup section. Click
“Execute” and the program will be sent to the processor.
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 17

Exercise 1: Ladder Logic Programming
Now that the program is downloaded…
Intro:
Preface •To put the ELC in RUN mode, click on the green RUN button in the toolbar or choose
COMMUNICATION>RUN from the menu.
•To monitor the Ladder Logic, click the Ladder Start Monitoring button in the toolbar
(there are popup tips that tell you what each button does when you mouse over
them), or choose COMMUNICATION>LADDER START MONITORING.
Support
Services
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Software
Overview
Hardware
Overview
Basics:
Exercises:
Go Chart
•Once you are monitoring the ladder, you can select a contact and right click to
change its state (see below).
•Note the status line at the bottom of the program that shows the info on current
programming mode (Replace or Insert), selected cell, scan time, number of steps
used/total capacity, communication indicator (blinking when comms are present),
ELC state, which port you’re connected to, baud rate, and ELC processor type.
Exercise 1:
Ladder Logic
Exercise 2:
Logic
Instructions
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 18

Exercise 2: More Logic Instructions
This exercise covers other basic functions like Set/Reset, MCS/MCR and Compare.
Use case: An injection mold machine has an automatic refiller for the plastic pellet reservoir. At the
beginning of the shift, the operator approaches the machine and presses the start button. The
filling mechanism automatically keeps the level in the reservoir between 10 and 100 lbs. If the
filler is already running, the operator has the opportunity to press a button that engages the filler
at a higher speed to fill the reservoir quicker.
•We’ve already created the cycle start command (M0); an output that will turn on a lamp that indicates the fact
that the machine is running (Y0); and an e-stop reference (M1).
•We will be adding 4 rungs in this exercise. To insert rows, right click in the space between the first rung and
the end statement and choose Insert Row.
TIP: If you can’t choose Insert Row, you may still be in Ladder Monitoring Mode! You can toggle in and out
of this mode by clicking the button in the toolbar.
•Just below the first rung and to the right of
the M1 contact, either type LD<= and click
the ellipsis button on the Input Instruction
Popup window or click the Application
Instruction tool on the toolbar and choose
LD<= from the pull down arrow next to
Application Instruction.The window to
the right will appear.
TIP: Get to know this window! The better you
understand this window, the easier it will be
for you to program your ELC. When you
use an advanced function block in ELCSoft,
this window is a big help in deciphering how
the program works. For each Application
Instruction that you choose in this window,
there is a specific description of its function
in the “Function” window.
•We will be storing the weight of the reservoir
in word D0. Since we want the motor on
when the wieght is at or below 10, we’ll set the OP1 window to D, the corresponding Device Number to 0, and
leave the Index window blank. The OP2 window will be Kto represent a constant decimal value, the Device
Number will be 10 (our minimum) and Index will again be blank.
•The output on this rung will be a SET instruction with Y1 as its reference (to turn on the “fill mechanism”).
Either type SET Y0 and press enter, or use the Application Instruction window, choose the SET instruction,
and enter Y and 1 respectively.
•Repeat the last 3 steps just below the rung you’ve been working on to create a rung that resets (RST) Y1
when the value of D0 is equal to or greater than 100. These two rungs should look somewhat like this:
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 19

Exercise 2: More Logic Instructions
•We now need to add a (very simple) Master Control Set and Reset to allow the
operator (activating bit M2) to speed up the main filler mechanism (M3) when the
main filler mechanism is running.
Intro:
Preface •At the beginning of the next rung, insert a normally open contact that references Y1.
Exercise 2: Logic
Instructions
Exercise 1:
Ladder Logic
Connecting to
the ELC
Software
Overview
Hardware
Overview
Basics:
Exercises:
Support
Services
Go Chart
•The output of this rung should be an Application Instruction MC with its operator
being N0 (N is the layer of what is more or less an extremely basic subroutine that
will function when Y1 is active).
•On the next rung, insert a normally open contact that references M2. This is just an
internal bit, but in real life, it could be an X (“real world” input) reference. This would
simulate the button that the operator can press that engages the filler at a higher
speed. The output on this rung is internal bit M3 (the act of the filler engaged at the
higher speed).
•On the next rung, there will be only an output that is an Application Instruction MCR
with its operator being N0 (to complete the MC with operator N0 above).
•When this is complete, you have finished the programming portion of this exercise.
Make sure your rungs look like this, then TRANSFER SETUP to the ELC.
NOTES: When monitoring this program, notice that you can right click on an object with a
numeric reference and choose Enter Value. When you do this, the window to the
right appears. Enter D0 in Device Name and enter K100 or higher in Current Value
to turn off Y1. Note that the
state of Y1 remains the same
between 10 and 100 so that the
filler either continues to run as
the weight rises from 10 to 100
or continues to be off as the
weight falls from 100 to 10.
When Y1 is on, you can activate
M2 and see M3 turn on. If Y1 is
not on, there is no way to turn
M3 on. If M3 is on when Y1 is
triggered off, it will turn off no
matter what the state of M2.
Exercise 2:
Logic
Instructions
Pub. No. TR05003001E For more information visit: www.EatonElectrical.com 20